Cellulosic product



Nov.'12, 1963 J. c. BLETZINGER 3,110,609

CELLULOSIC PRODUCT Filed April 30, 1959 4 Sheets-Sheet 1 Nov. 12, 1963J. c. BLETZINGER CELLULOSIC PRODUCT 4 Sheets-Sheet 2 Filed April 30,1959 Nov. 12, 1963 Y J, c.-BL.ETZINGER 3,110,609

' CELLULOSIC PRODUCT Filed April 30, 1959 4 Sheets-Sheet 3 III Nov. 12,1963 J. c. BLETZINGER CELLULOSIC PRODUCT Filed April 30, 1959 4Sheets-Shqej. 4

United States Patent CELLULOSIC PRODUCT John C. Bletzinger, Neenah,Wis., assignor to Kimberly- Clark Corporation, Neenah, Wis, acorporation of Delaware Filed Apr. 30, 1959, Ser. No. 810,012 6 Claims.(Cl. 117-25) This invention relates to improvements in fabric webs madewholly or partially of a layer of loosely matted cellulosic fibers, andit is also concerned with products in which the improved fabric is acomponent; and with.

amount of fiber in the web; and to provide these and other desirablecharacteristics in material which may be manufactured economically andat low cost.

Further objects of the invention are to provide practical and efficientmethods and apparatus for producing the aforesaid material, and toprovide improved products fabricated wholly or in part of said material.

Other objects and advantages of the invention will be understood byreference to the following specification and accompanying drawings, inwhich:

FIGS. 1, 2, 3 and 4 are plan views of portions of fabric materialrespectively embodying different forms of the invention, these viewsbeing on substantially enlarged scales, about twice actual size, tobetter illustrate the respective constructions; I

FIGS. 5 and 6 are respectively plan and side view illustratio'ns'ofstill another form of the fabric;

FIG. 7 is a plan view on an enlarged scale, about four times actualsize, of one form of carrier web or backing sheet which may be employedin certain forms of fabric made according to the invention;

FIG." 8 is a schematic representation of a method and apparatus forproducing the improved fabric; I

FIGS. 9, 10, 11, 12, and 13 are schematic illustrations of variousapparatus elements which may be employed to produce various forms offabric according to the invention;

, I, FIGS. 14 and 15 are schematic representations of other means forproducing the improved fabric;

circumference.

.FIG. 16 is a perspective illustration of a catamenial napkin accordingto, the invention;

FIG. 17 is a plan view of a portion of another form of sanitary napkinwrapper material according to the invention; and,

FIG. 18 is a plan view of padding material made according to theinvention;

FIGS. 19 and 20 are plan views on an enlarged scale of a portion of.sanitary nap kin wrapper material embodying still different forms of theinvention;

FIGS. 21 and 22 are plan and perspective views respectively on anenlarged scale of a portion of another embodiment of the inventionespecially suitable as a sanitary napkin wrapper; and

FIG. 23 is a perspective illustration napkin utilizing the wrapper ofFIGS. 21 and 22.

The fabric. construction represented in FIGURE 1 comprises a base orcarrier web 1 of gauze-like fabric consisting of lengthwise andcrosswise threads 2 and smspectively, which may or may not beinterwoven, and an applique 4 of cellulosic fibers. The gauze web 1 ishere represented as being 16 x 8 construction, that is to say,

of a catamenial 3,119,609 Patented Nov. 12, 1963 embodying 16longitudinal threads per inch of width and 8 crosswise threads per inchof length of the fabric. The thread count of 16 x8 is merely exemplaryand not critical; it may be more open, such as 4 x 4, or less open, thisdetail being not critical but subject to variation to suit the end usefor which the fabric is intended.

Secure attachment of the fiber applique to the carrier web is usuallydesired. Frictional attachment may be suitable for some purposes, but itis usually preferred that some form of adhesive attachment be employed.

When the carrier web is made of woven gauze, many desirablecharacteristics are obtained when adhesive is applied in such a mannerthat blobs (FIGURE 7) of adhesive will occur at alternate threadintersections where the crosswise threads 3 cross over lengthwisethreads 2 on one side of the fabric, and so that ribbons 6 of adhesiveoccur along the lengthwise threads 2, such adhesive ribbons 6 being moreor less discontinuous along the lengths of said threads, small breaksoccurring at irregular intervals as indicated at 7.

The crosswise threads 3, are generally free of adhesive except where theblobs 5 occur, and this freedom from adhesive and the breaks along thelongitudinal threads contribute substantially to preservation to highdegree, of the normal flexibility or limpness and softness of thecarrier web material. Said adhesive blobs 5 engage the intersectingthread portions so as to bind said threads together to thereby stabilizethe relationship of the threads of the gauze. This stabilizing elfectmakes it highly practicable to, use gauze of very open weave, such as,for example, 4 x 4, which otherwise is subject to such severe fraying asto be unusablefor purposes where uniformity of appearance and of threaddistribution is important.

The fiber applique will, of 4 course, be bonded to the thread webwherever fibers engage adhesively coated portions of the web, suchpoints of engagement occurring at intervals. To attain the-mosteffective adhesive bonding, some form of pressing or calenderingoperation is usually employed to insure embedment of the fibers in theadhesive on the carrier web. Y

I When the carrier web consists of unwoven longitudinal and crosswisethreads, said longitudinal threads are preferably coated with adhesivealong their lengths by suitable roller means whereby the adhesive willbe caused to envelop less than the entire circumference of thethreads,,for example, about one-third or one-half the The extent of suchenvelopment is controllable by suitably adjusting the thickness or depthof adhesive, coating carried by the applicator roll. When the adhesiveis so applied to only a part of the circumference of the threads,twisting or turning of the threads on their own axes during the deliverythereof into the aforesaid cross-laid gauze-like'formation, will causesome ofthe adhesivelycoated thread surface to appear on each face of thecarrier fabric so that non-woven fiber appliques may be adhesivelybonded to either or both faces of such carrier fabric, the bondingoccurring at spaced points. Also, the threads will :be bonded to eachother at some but not all of their crossings and such bonded crossingswill usually be fairly well distributed over the area of the web and beeffective to stabilize the thread web in the form in which they arecross-laid. T he lengthwise threads may'also have adhesive appliedthereto around their entire circumferences (for example, by being passedthrough a bath of adhesive) with bonespondingly increased bonding of thecross threads tothe V longitudinal, adhesively coated threads, and ofthe fiber applique to the carrier web; this'is desirable for some is notrequired.

The adhesive, whether applied in the manner described or otherwise, ispreferably of a permanently flexible kind, so that hardening andstiffening of the gauze fabric due to the presence of the adhesive isthereby further avoided to a substantial degree. Also, to this same end,said adhesive is preferably of a type which remains substantiallysurfaced on the threads and does not penetrate the same. The kind of.adhesive used may vary according to the manufacturing processes to beused in producing the wrapper material and according to thecharacterictics desired in the finished product. Resinous adhesiveswhich can be applied as organisols or plastisols have been found to beespecially suitable, it being practicable to formulate the same tosupply the required strength of bond, water insensitivity, permanentflexibility, and softness. Also, such adhesives embody thermoplasticproperties which can be advantageously utilized. The said adhesives mayalso be formulated to have, in addition to the aforesaidcharacteristics, the tendency to remain surfaced on the threads ratherthan to soak into the same, this surfacing tendency being also helpfulin avoiding hardening and stiffening of the fabric by the adhesive.

The fiber component 4 may consist of cotton fibers or other suitablefibers, or mixtures of fibers, which are selected to suit the end use ofthe product. Synthetic fibers comprising rayon, nylon and others, andnatural jute and other known fibers may be employed if desired. Thisfiber component is in a patterned form, for example, in a network,formed in this instance, of intersecting, relatively perpendicularly butdiagonally arranged sets of spaced parallel lines or bands 8 and 9. Thispattern leaves openings 10 in which there may be practically no fibersor a relatively few fibers as compared with the quantity thereof in theareas 8 and 9 of fiber concentration. It should be observed that the twosets of intersecting lines or bands of fibers are, in this instance,simultaneously formed as an integral pattern and that the intersectionareas 8a of the pattern are of the same weight as the other areas ofsaid lines or hands.

In a carrier web backed fabric such as shown in FIG- URE 1, the weightof fiber'in the patterned applique may be within a very wide range; thelimits of this range are not critical but depend upon the purpose forwhich the fabric is intended and upon the kind of fibers employed. Formany purposes, the weight of the fiber applique may be so low that theapplique would not be self-sustaining in web form.

When material according to FIGURE 1 is to be used as the wrapper aroundan absorbent pad, as in a catamenial napkin (FIGURE 16) in which highpermeability of the wrapper is desired, the weight of fibers in theareas of fiber concentration, is preferably Within a range of about 1 /2to 6 grams per square yard, basis weight, and the weight of fibers inthe areas 10 may be much lighter, for example, at a rate of .S gram andless basis weight, per square yard. "The fibers in the applique may beof bleached comber cotton which usually includes fiber lengths rangingfrom about inch to about 1 inch or more, a large proportion of the fiberbeing of'an intermediate length of around A of an inch, and about of thefibers being one inch or more in length. This fiber make-up is also ofgeneral utility for other applications of this invention in which otherv"basis weights of fiber are used, but other kinds of fibers and blendsof two or more kinds may also be used.

The weight of fiber in the various areas mentioned depends upon thedesign of the pattern employed, the Width of the lines or bands 8 and 9or the area of other design elements and the spacing thereof, thethickness or depth, and the -density'to which the fibers are depositedin said areas, the kind of fiber employed, and perhaps other factors.Because of the variable applique pattern factors, it is not practicableto specify the weight of non-woven fibers per square yard of thepatterned fiber applique. The words basis weight as above and hereitinafter used, means that the fiber weight in the patterned areas is suchthat if like fibers were distributed to the same depth and densityuniformly aver an area of one square yard, the weight of the uniformlydistributed fiber in such area of one square yard, would be thespecified basis weight of the patterned applique.

Some of the fibers in said areas 3 and 9 may extend in the direction ofthe lines or bands but a large portion of said fibers, when deposited byair-laying, and even by carding, are disposed haphazardly in said areasso that a unitary, ungrained, velvety or felt-like appearance isproduced in said areas. For some uses of the fabric, the amount offibers collected in these areas 8 and 9 may be made quite heavy and forother uses, such as catamenial napkin wrappers as above referred to, thefiber weight may be held low enough to provide high permeability even inthe areas of fiber concentration. The areas 10 may be practically devoidof fibers but when fibers are present in said areas, most of them extendout of the. areas of fiber concentration. The relatively few fiberswhich occur in said openings or areas 10 do not materially affect thenormal permeability of the carrier web in said areas.

When the material is destined for use as drapery, curtain, or camouflagepurposes, the pattern, and the weight of fiber in the areas of fiberconcentration and fiber I paucity or dearth respectively will beselected to obtain the appearance and other characteristics desired. Forexample, .for camouflage purposes wavy and irregular patterns areusually preferred, and the weight of fibers may be within a range ofabout 1 to 20 grams per square yard, basis weight, but usually withinthe lower portion of that range. Similarly, when the material is to beused for padding purposes, the weight of fibers in the fiberconcentration areas may be substantially increased, for example, intothe upper portion of said range of 1 to 20 grams or more. Also, thepattern in which the fibers are collected may be made to provide morefiber covered area than fiber-free area or vice versa, depending, ofcourse, on the requirements of the use to which the material is to beput.

The amount of fiber required to form the patterned material is generallyless than the amount required to produce material of equivalent utilityin which the fiber is spread uniformly over the entire area of thefabric, i.e., without pattern. An important saving in the cost of fiberis accordingly attained by employing a patterned distribution of fiber,and high speed production of the fabric is more easily effected since arelatively small volume of fiber is required per unit of time to form apatterned arrangement. I v

The intertwined relationship of the fibers in the fiber componenttogether with the adhesive bonding of fibers to the gauze web will causethe fiber component to be effectively held as an entirety to the carrierweb. A few loose fibers may occur and if these are objectionable, theymay be removed in any suitable manner, for example, by suction orblowing, by a shaking or beating operation, or by a combination of anyof these. The occurrence of loose fibers which will dust oif the web maybe largely avoided by using fibers of suitable length so that all of thefibers will be more or less intertwined or interattached as aforesaid,some of the fibers being anchored to the thread carrier web by engagingadhesive carried by the latter. It may be" observed that in 16 x 8gauze, the longitudinal threads are spaced apart only one-sixteenth ofan inch and that most of the fibers in the fiber applique will overlieseveral of the adhesive-bearing longitudinal threads so as to insureadequate bonding of the applique to the gauze. HThe'few fibersin theintervening areas will also. usually be similarly vadhesively bonded toseveral of thelongitudinal threads of the carrier web.

Another way in which the fibers may be bonded to the carrier web,whether in the form of transversely spaced longitudinal threads as inFIGURE 3 or woven or cross-laid longitudinal and transverse threads asin FIGURES 1 and 2, or some other form, is to incorporate a smallpercentage of thermoplastic fibers in the threads or other material ofthe carrier web component, and to subject the carrier web and fiberapplique to a hot calendering operation whereby the thermoplastic fibersin the carrier web are reactivated and some of the fibers of theapplique pressed into such reactivated material to become bondedthereto, the reactivated material and said fibers also being therebycaused to become adhesively secured to adjacent elements of the carrierweb.

Still another method for bonding the fiber applique to the carrier webis to incorporate a small percentage of thermoplastic fibers in thefiber applique andsubject the assembled carrier web and fiber appliqueto the aforementioned hot calendering operation to reactivate thethermoplastic fibers for adhesive bonding to other fibers and tocontiguous portions of the carrier Web. Thermoplastic fibers may, ofcourse, be incorporated in both the carrier web and in the fiberapplique. The use of thermoplastic fibers in either or both the carrierweb and the fiber applique, produces satisfactory bonding for manypurposes, and the use of such binder fibers and the said hot calenderingoperation is advantageous in that it avoids the use of wet liquidadhesive and thereby avoids possible gumming up of the apparatusemployedfor producing the fabric, and the need for constant watchfulnessand frequent cleaning to maintain satisfactory operating conditions.Such calendering also attains other often desirable results such assmoothing of the faces of the fabric,

longitudinally extending, transversely spaced threads indicated at 13and an applique 4b of fibers in the form of a plurality transverselyextending, longitudinally spaced bands, or areas 14 of fiberconcentration between which are areas 15 in which there is a relativescarcity, if not an absence, of fibers. The longitudinally extendingcarrier web threads constitute means for holding the fiber sections 14in spaced relation, said fiber sections being preferably adhesivelyattached to said threads although flattening carrier web threads andespecially the crossover portions thereof in woven fabric, and generallyimproved integration or unification of the components in the material.

The hot calendering operation for reactivating thermoplastic adhesiveand fibers may be replaced by liquid or vapor solvent treatment of thethermoplastic material to render the same active for bonding purposes,and acalendering operation may be employed to obtain embedment of thestable thread and fiber elements in the reactivated thermoplasticmaterial.

When thermoplastic fiber is incorporated in the fiber applique forbonding purposes to the extent'of as little as five percent of the totalvolume of fibers, a useful measure of fiber attachment to carrier weband of fiber to fiber bonding or fiber applique integration will beobtained. The percentage of thermoplastic fibers may be greater thanfive percent to obtain correspondingly increased bonding.

The fabric structure shown in FIGURE 2 is similar to that shown inFIGURE 1 in that the FIGURE 2 structure also embodies a thread carrierweb or backing element 1 and a fiber applique designated 4a insomewhatdifferent form than the applique 4 of FIGURE 1. The applique 4acomprises a plunality of transversely spaced, parallel lines or bands 11of fibers, and intervening areas 12 which are substantially free of suchfibers or contain only gossamer films thereof similar to the fillingwhich occurs in the areas 10 of the FIGURE 1 structure. The bands 11 andintervening areas 12 extend longitudinally of the fabric. Some of thefibers of the bands which constitute the applique 4a, will contactadhesive applied to the carrier web component so that said applique willbe adhesively bonded to the gauze. The bands 11 are preferably of awidthgreater than the spacing of the longitudinal threads of the carrierweb so as to insure engagement of most of the fibers in each band withat least one such thread. For some purposes, the carrier web 1 mayconsist of only crosswise extending, longitudinally spaced threads tosupport the transversely spaced fiber bands in the desired spacedrelationship, the fiber bands themselves being made strong enoughtosupply the required longitudinal strength.

The fabric structure shown in FIGURE 3 comprises a backing or carrierweb 1a in the form of a plurality of mere frictional attachment may besufficient for some purposes.

The fabric construction represented in FIGURE 4 is an all unspun,separated fiber construction comprising fibers deposited in a networkpattern consisting mainly of mutually spaced lengthwise and crosswisefiber concentration bands or areas 16 and 17 respectively, which leaveopening areas 18 having a relatively small number of fibers therein.

The fiber arrangement in the FIGURE 4 construction is very similar tothat described above in connection with FIGURE 1 but in this instancethe lengths of relatively transverse areas of fiber concentration arerespectively parallel and normal to the length of the fabric, but itshould be observed that they may be diagonally arranged as in FIGURE 1if preferred.

In the light weight fabrics made entirely of unspun fiber, suchas'typified by the structure shown in FIG. 4, the fabric requiresstrengthening or reinforcement for most purposes. One way to effect'suchreinforcement is to apply lines of adhesive binder material as indicatedat 19 to the fiber bands 16and 17, to provide for adhesively bonding thefibers in said bands to each other. The adhesive may be of a type whichwill maintain ribbon-like continuity and of itself impart tensilestrength .to the fabric, but because of the discontinuous form in whichthe adhesive is preferably applied, its main strengthening effect isprobably incident to said bonding of some of the fibers to each other.;Such lines of binder should be in such spaced, relationship that a verylarge proportion of the fibers will be engaged by at least one'line ofadhesive; whenso spaced, it will be found that substantial longitudinaland crosswise tensilestrength is imparted to the fabric. The spacing ofthe lines of binder'will, of course, be dependent largely on the lengthsofthe fibers in the applique. This method of strengthening a nonwovenweb of fibers is particularly applicable to webs having a basis weightof about 4 grams or more per square yard. Below that weight, it isdifficult to print adhesive on the web in a commercially practicablesense, and a suitable carrier web is indicated for reinforcing purposes.This discontinuous adhesive bonding is especally desirable in connectionwith wholly non-woven fabrics such as represented in FIGURES 4 and 5,but it may also be applied to the carrier backed fabrics of FIGURES l to3 inclusive. A method and means for applying adhesive in the illustratedpattern will hereinafter be explained. I

The fabric illustrated in FIGURES 5 and 6 is similar to that shown inFIGURE 4 in that it involves a network formed of longitudinally andtransversely extending bands and ribbons of fiber respectivelydesignated 16a and 17a but in this instance, the ribbons 16a are formedindependently of the bands 17:; so that the ribbons 16a cross over thebands 17a and produce increased thickne'ss'pon tions 16b in thecross-over areas. The areas 1 a surrounded by the fiber areas 16a and17a may be totally devoid of fibers or they may have a relative paucitythereof as compared with the areas 16a and 17a. The fiber areas 16a and17a may be adhesively bonded together by the application of adhesive inthe manner represented in FIGURE 4, either on top of the overlying fiberband-s 16aorion top of the bands 17a prior to application of the fiberribbons 16a. If the adhesive is applied over the ribbons 16a, then itshould be of such a character that it will sufiiciently penetrate thesaid ribbons to effect d the required bonding to the underlying bands17a. If the adhesive is applied to the bands 17a, then it should be ofthe above mentioned character which will remain substantially surfacedon the fibers for efiicient bonding engagement with the subsequentlyapplied fiber ribbons 16a. The word ribbons is used in reference to thefiber areas 16a to indicate fairly sharply defined self sustaining websof fibers formed, for example, by a carding engine, whereas the termband has been applied to fiber areas which may be of lighter weight andlesser integration, formed, for example, by air laying. However, itshould be observed that it is not necessary that these two specificallydiflEerent forms of fiber areas be employed. All of the fiber areas maybe produced by air laying if desired.

The increased thickness cross-over areas 16b are especially desirable inconnection with the production of packaging material as hereinafterexplained in connection with FIGURES l7 and 18 of the drawings.

If fabric material according to FIGURES and 6 is combined with a carrierweb of gauze such as represented in FIGURE 7, and the combined materialused as the Wrapper of a sanitary napkin, said extra thickness fiberportions 16b may be advantageous in their amplified effect in shieldingthe gauze threads from engagement with the body. In the fabricconstructions represented in FIGURES 4 and 5, portions of one set of thefiber bands or sections which extend between and interconnect the bandsor sections of the other set constitute means for holding the'latter inspaced relation.

The fiber supply for the described wholly non-woven fabrics maybe theabove mentioned comber cotton. In some instances, it may be preferred toemploy fibrous material having a larger percentage of long fibers.

The fiber patterns represented in FIGURES 1 to 6 inclusive embodystraight lines or hands and ribbons of fiber which impart to the fabrictensile strength in the direction of the lengths of such lines or bands.The crisscross line patterns of FIGURES 1 and 4 provide good tensilestrength in two relatively transverse directions and result in goodtensile strength in all directions. However, it is not essential thatthe pattern be based on straight line fiber formations since curved orundulating lines, and any desired regular, symmetrical or irregularunsymmetrical pattern may be employed. However, when tensile strength isdesired in non-woven fabric (without a back gauze, paper or othersufiiciently continuous backing web is employed, the unspun fibercomponent may be in discontinuous pattern embodying dots, dashes,circles and an endless variety of other forms, and one or more differentfiber area shapes may be employed in the fabric.

For some purposes the backing material of fabric constructions such asshown in FIGS. 1, 2 and 3, may be formed of threads of adhesive materialsuitably deposited and on which the fiber applique may be deposited. If

such adhesive material threads are of thermoplastic adthreads), iswithdrawn from a suitably mounted supply roll 20 (FIGURE 8) or otherwisesuitably delivered to and carried forwardly by the horizontalupper-reach of a conveyor belt 21 which is suitably, preferablycontinuously, propelled. The belt 21 travels around suitably positionedguide rolls 22, 23, and 24. One or more of these rolls may be adjustablymounted or suitably biased to act as a take-up roll for maintaining thehorizontal upper reach of the belt as taut as desired. Additionalsupporting or guide rolls may be provided as needed.

Frictional engagement between the conveyor belt 21 and the carrier webmaterial is usually suificient to cause the carrier web to follow theconveyor belt but suitable pressure rolls may be employed if needed ordesired, for

effecting driving engagement of the carrier web with the conveyor, belt.

Adhesive is applied to said carrier web 1 while it is supported by saidconveyor belt, by means of adhesive applying or printing equipmentrepresented at 25 which is constructed and operated to apply theadhesive in the desired manner, for example as described in connectionwith FIGURE 7. A drying device 26, suitable for partially drying orsetting the kind of adhesive employed, is provided. When the adhesive isof a character which permits it, such as a resinous, thermoplasticadhesive in plastisol or organosol form, the drier 26 is so operatedthat the adhesive remains active at least on its surface during thepassage of the carrier web into and through the area of operation ofapparatus by means of which the fiber component is applied to the web.

A bat 2 7 of the selected comber cotton or other fibers or blends offibers is withdrawn from a suitably supported supply thereof and fedinto engagement with a picker or other suitable divellicating roll 28which is rotated at high speed, thereby to break the bat 27 down into astream 29 of separated fibers which streamflows toward the forarninousweb 1 which, as indicated in FIG. 8, is now carried crosswise of saidfiber stream by another conveyor 3b, to intercept the fibers and collectthe same on said web 1. The conveyor belt Ed is a foraminous or screenwire belt which is continuously propelled and guided by suitable rolls31. A suction box 32 placed under this forming belt or screen, aids thedeposition of the fibers. on the carrier fabrics. The divellioatingapparatus may include provision in addition to the suction box forinducing air currents to carry the fibers and to guide or control thepath of said stream of fibers.

The pattern or net-like arrangement in which the fibers are deposited isdetermined: by the pattern of the forming screen. The network fiberpattern shown in FIGURE 1 may be produced by filling in the formingscreen areas corresponding to the openings 10 so as to leave permeablelines or,strips in the screen substantially corresponding to the fiberband areas 8 and 9. The foraminous screen 30 is usually quite long andcostly and such treatment of the screen would itself be quite costly andwould limit the use of the screen to the production of a single fiberpattern. This objection may be avoided by incorporating the desiredpattern in an auxiliary or pattern screen 33 of much shorter length thanthe screen 3%.

Such an auxiliary or pattern screen 33 may be guided around suitableguide rolls 34 in such a manner that the upper reach of said patternscreen is disposed intermediate the suction box 32 and the upper reachof said forming screen 30, preferably in engagement with or closeproximity to said forming screen. The pattern screen 33 may be driven atthe same linear speed as the forming screen 39 or, in some instances,said screens may be operated at difierent rates of travel. The pat ternscreen 33 may be of the same construction as the forming screen 21, butsaid patter-n screen has appropriate areas closed by being filled withsolder or fiexible plastic material, or such areas are blocked out bybeing covered with imperforate elements suitably secured to the screenbelt. Said pattern screen may also be in the form of a solid metal orother belt perforated to provide the de sired pattern. In FIGURE 9, thepattern member 33 is represented as having areas 35 closed to leave anopen pattern of perforated or foraminous forming wire as indicated at36, such pattern corresponding substantially to the network pattern ofthe fiber bands 8 and 9' of the material shown in FIGURE 1.

The pattern screen or wire 33, travelling in close contact and in unisonwith the overlying forming screen 30 will, in eifect, impart to saidscreen 30 the same pattern as occurs on the pattern screen so that thefiber in the stream 29 will be collected in concentrations coincidingwith the pervious pattern areas 36 on the pattern screen 33. Some fiberwill, however, tend to spill or fall over the imperf-orate areas 35 sothat in such areas, which correspond to the areas 10 in the FIG. 1,product, there will usually be a few overlying fibers. In someinstances, some or all of the imperforate areas 35 may be pro vided Withone or more perforations, such as an opening 37 represented in dottedlines in FIGURE 9, to induce the disposition of a few fibers in saidareas.

In addition to the above mentioned reduced cost of preparing the shorterpattern screen 33 instead of the longer forming screen 30, and theindicated feasibility of providing as many as may be desired of theshorter pattern screens for versatility in respect to the patterns whichmay be produced, the provision of such shorter pattern screen greatlyfacilitates the changing of the pattern screen. A short screen belt maybe removed and replaced by another with much less work than is requiredfor similarly handling a long, full length screen like the formingscreen 30; hence, pattern changing may be speedily etfected and idletime of the apparatus because of such changing, held to a minimum.

Fibers pneumatically deposited in the manner represented in FIGURE 8,will be more or less intertwined and cohesively interattached so thatthey will form a substantially continuous web. When the weight of fibersin the main fiber areas is within the lower portion of the hereinbeforeindicated weight range of 1 /2 to grams per square yard, basis weight, alarge proportion of the fibers will engage the adhesive carried bythreads of the gauze web, whereby the fiber applique, as an entirety,will be strongly bonded to the gauze or other carrier web; this bondingmay be improved somewhat by the application of either or both heat andpressure to the composite web, as by means of a calendering operation.

A calendering operation may be performed by means of a suitable calenderroll stack 38', the composite fabric being passed between a pair of therolls thereof so as to cause the adhesive engaging fibers to be pressedinto the "adhesive, thereby to improve the adhesive fiber-tocarrier webbond and also the adhesive fiber-to-fi'ber bond wherever such a bondoccurs. One or more of the calender rolls may be heated to thetemperature required to soften or reactivate the thermoplastic adhesivematerial to facilitate embedment of the fibers as aforesaid and means,such as a pneumatic device 39 may be provided in operative relation tothe travel of, the composite web from the calender stack, to cause airto flow through the web or across one or both surfaces thereof to removeloose fibers and to cool and set the thermoplastic adhesive, after whichthe composite web may be wound into a roll 40 by suitable windingmechanism typified by rollers 41. Guide rolls such as indicated at 42,43, and 44 may be employed for guiding web to and from the calenderstack and to the winding mechanism. (Printing equipment indicated at 45is not used in the preparation of composite fabric according to FIGURE 1although it may be use-d to add reinforcing lines of adhesive similar tothose described in connection with FIG. 4.)

The longitudinally ribbed or banded fiber applique in the product shownin FIGURE 2 may be produced by the apparatus above described except thatthe pattern screen 33 is eliminated and a series of longitudinallyextending parallel, transversely spaced bafile bars 46 (FIG. 11) areprovided immediately above the forming screen 30 to cause fiber to bedeposited primarily in the bandforming areas between said bafile bars.The bafile bars may be supported by suitable frame work or, asillustrated in FIG. 11, by the walls of a housing 47 which enclosesthearea of fiber deposition above the suction box 32. A small amount ofthe fiber will be carried under such bars by air currents drawnthereunder and thence into the suction box 32 so that the areasintermediate said main band areas will usually present 'at least a fewfibers. This longitudinally ribbed pattern of fiber facing may also beproduced by omitting the pattern screen 33 and providing a series oflongitudinally extending, transversely spaced baffle bars 48 across thetop of the suction box as shown in FIGURE 12.

A very sharp edged longitudinally ribbed pattern exhibitingsubstantially fiber free areas intermediate the bands of fiberconcentration, may be produced by employing simultaneously, the .baflles46 in the bottom of the forming chamber and the baffles 48 at the top ofthe suction chamber, the baffles 46 being registered with the baffles 48in vertically superposed relationship. Such an arrangement evidentlyprevents the flow of fiber-bearing air under the battles 46 andaccordingly produces very sharply defined fiber bands corresponding tothe fiber bands 11 in FIGURE 2. I

The web shown in FIGURE 3, with its crosswise extending bands of fiber,may be manufactured on apparatus such as represented in FIGURE 8, thepattern screen belt 33 being replaced by a. similar belt 33a (FIGURE 10)having crosswise extending ribbon-like areas 49 closed or blocked out ina manner similar to that in which the areas '35 (FIGURE 9) are closed.If desired, the areas 49 may be blocked out by applying suitable tapestrips (as indicated in FIGURE 10) to the screen belt, such tape stripsbeing adhesively or otherwise secured in place on the screen. If thelongitudinal thread carrier web of FIG. 3 is desired, threads to formthe parallel thread backing 1a would, of course, be substituted for thegauze web 1 and such threads may be coated with adhesive by means of aroller applicator as indicated in FIGURE 8 or by being passed through abath of adhesive. The adhesive bonding lines 19 in the FIGURE 4 fabricconstruction may be applied by employing the printing mechanism 45 inthe apparatus represented in FIGURE 8. The said printing mechanismcomprises a printing roll 50 (See also FIGURE 13) having raised printingsurfaces or ribs 51. The printing roll being properly adjusted relativeto the path of travel of the fiber web, will print only on the raisedareas produced by the fiber bands 16 and 17 so as to: produce thediscontinuous adhesive bonding pattern represented at 19 in FIGURE 4.Theareas 18, (FIGURE 4) having but little or no fiber, will receive noadhesive imprint. Adhesive binder appliedin the manner just described,when dried, naturally or artificially, will effectively bond fiberstogether at intervals along the lengths of the hands. When the printingunit is used, it is preferable that it print onthe web after calenderingthereof as shown in FIG. 8, whereby a better printing surface isimparted to the fiber applique. Intermittent bonding, as produced byprinting adhesive on the fiber band areas in the manner just described,may also be effected when the fiber bands are made wholly or partiallyof thermoplastic fibers, by employing the printing roll 50 as a hotcalender roll to heat and reactivate portions of thermoplastic fiberswhich occur in such positions as to be attested by the rib areas 51 ofthe roll. Subsequent calendering of the fabric, although not essential,will insure effective adhesive interengagement of the softenedthermoplastic material and contiguous threads and fibers.

The fabric shown in FIGURES 5 and 6 may be produced by apparatus such asrepresented in FIGURE 14. The transverse fiber ribbons 17a are formed bydeposition from suitably divellicat-ing mechanism 28 which delivers thefiber stream 2% to the forming wire 36. A pattern screen of the formrepresented at 33a in FIG. 10, provided with transverse bars or closurestrips 49, is associated with said forming wire 3% so that the fiberswill be collected on said forming screen in said transverse bands 17a,the suction box 32 being employed to aid the deposition of the fibers onthe forming wire. The longitudinally extending fiber ribbons 16a areformed independently of the bands 17a, by means of a carding engine 52which delivers a plurality of mutually independent fiber ribbons or webs16a separated from each'other according to the spacing desired, theribbons being delivered on top of the bands 1711. These separated fiberribbons are obtained from the card by the use of appropriate dofiingcombs. Printing mechanism 45 may be interposed between the divellicatingmechanism and the card as shown in FIG. 8, or positioned after the card,to apply adhesive respectively to the transverse fiber bands 17a beforeoverlaying the card-formed ribbons tea, or to the latter, as may bedesired. If desired, the web may be calendered before printing toimprove the printing surface on the fiber bands or ribbons. It will alsobe apparent that thermoplastic fibers may be incorporated in either orboth sets of fiber bands and such thermoplastic fibers reactivated tobond the crossing portions of said bands together by the application ofeither or both heat and pressure or by any other suitable means.

The FIGURE 15 apparatus comprises fiber bat divcllicating means 52',substantially like that employed in the FIGURE 8 apparatus, but insteadof the costly forming belt 30 and pattern'screen 33 of FIGURE 8, thereis provided a foraminous forming cylinder 53 suitably rotatably mountedand rotated in the path of the stream 54 of separated fibers produced bythe divellicating mech anism. If the fabric is to be formed on a backingWeb 1, such a web may be guided by rollsSS and 56 to and from theforming cylinder. A suction tube 57 arranged diametrically of theforming cylinder and connected by suitableconduit means 58 to a suctionfan, may be provided to aid the deposition and matting of the fibers onthe surface of said roll. Said roll surface may be made of screen wireor other foraminous material provided with the desired pattern formingpervi ous and impervious areas.

One example of utility of the described fabrics is represented in FIGURE16 in which the gauze reinforced fabric of FIGURE 1 constitutes thewrapper 59* around an absorbent pad Gil in a :catamenial napkin. Thiswrapper 59 is highly permeable as above explained and permits themenstrual exudate to readily penetrate the wrapper to be absorbed by thepad 60-. The highly permeable character of the wrapper material tends toavoid the accumulation of moisture on the surface of the napkin and thisrespect contributes a highly desirable comfort characteristic to thenapkin. Also, the bands or ribs of fiber provide a sheathing orshielding effect over the threads of the gauze or other thread-formedbacking web so that the threads are held out of direct engagement withthe body of the wearer of the napkin. The very uncomfortable abrasiveeffect of threads in a gauze or other thread containing sanitary napkinwrapper is thereby eliminated from the napkin represented in FIGURE 16.The said sheathing effect is also applicable to other santitary napkinwrapper webs such as paper or other Webs which, in the absence ofsuitable protective means, tend to chafe. The described constructionsprovide surface smoothness and softness or anti-abrassiveness equivalentto that of wrappers containing substantially greater amounts of fiberdistributed uniformly over the entire area of the wrapper. Hence, thedescribed patterned fiber lay construction attains improved results andalso economy by the use of a reduced amount of fiber.

For the greatest anti-chafing effect, it is preferred that the areas offiber paucity have a light lay of fibers and this may be attained as anincident to production of the fabric by means of the described methodsand apparatus and by selecting a pattern in which the fiberconcentration areas are not too greatly spaced and whereby the desiredamount of fiber will extend over said areas of fiber paucity.

The unspun fiber applique is preferably on the outside of the wrapper 59to attain the maximum effect thereof but it may be located on the insideof the wrapper in the normal use of the napkin without whollysacrificing the beneficial attributes of the wrapper. Many of the fibersof the applied bands project through the carrier Web to provide saidchafe preventing, thread sheathing effect on the side of the fabricopposite to that on which the fibers are deposited. Permeability willremain about the same whichever side of the wrapper carries the fiberapplique but the chafe preventing effect thereof will best be attainedwhen the fiber component is on the outside.

The unspun fiber component also imparts to the surface of the napkins adesirable overall smooth feel notwithstanding the presence of areas inwhich there are but few fibers. The overallness of this smooth feel isprobably somewhat dependent on the thickness and kind of fiber depositedin the fiber ribbon areas and the spacing thereof from each other, andit is accordingly capable of adjust- .rent by appropriate selection inrespect to these details.

The provision of theareas of fiber dearth or relative fiber paucity,contributes to the preservation in the wrapper material of a largeproportion of the normal softness I or lirnpness of the open mesh gauzematerial forming the carrier web or baseof the wrapper. Such limpness ofthe material greatly facilitates folding of the material about the pad,especially by high speed automatic machinery. This lirnpnesscharacteristic is also desirable in that it permits the wrapper toconform closely to the enclosed pad body whereby good appearance of thecatamen-ial napkin is obtained.

The reduced amount of fiber in the wrapper also results in reduced bulkin napkin end tabs with attendant benefits to the wearer of the napkin.

Another form of sanitary napkin wrapper fabric shown in FIG. 17 embodiesareas of relative fiber concentration and dearth 6 1 and 6 2respectively in a checker-board pattern of fiber applique on a carrierweb 63 which may be of any suitable open mesh or highly perviousmaterial.

The wrapper shown in FIG. 17 also has fiber applique bands 65 whichextend lengthwise of the wrapper and are adapted to cover the side edgesof the absorbent pad when the wrapper is folded around such pad. Onelongitudinal margin, 66, of the carrier web is left free of fiberapplique material so that when the wrapper is folded around a pad andsaid margin is lapped over the opposite margin there will be but asingle thickness of fiber appli que material in the area of said lappedmargins.

The wrapper of FIG. 17 may be applied to the pad with the fiber appliqueeither inside of the wrapper or on the outside thereof. The fiberapplique may be bonded to the carrier web by means of thermoplastic orother suitable adhesive, for example, one in the form of a plastisol oran organosol as previously mentioned herein, and this adhesive bondingis especially desirable when the fiber applique is on the outside of thewrapper. The described methods of producing patterned fiber area websfacilitates the production of wrappers like that shown in FIG. 17 withfiber applique areas arranged to fit and cover selected pad areas. Ifdesired, the band areas 65 may be made of a length which corresponds tothe length of the pad edges so as to reduce fiber applique bulk in theattachment tab end portions of the wrapper.

Other embodiments of fabrics of this invention, especially suitable foruse as sanitary napkin wrappers, are

shown in FIGS. 19-22. The fabrics shown have relatively open centralportions extending longitudinally thereof, those portions being ofpatterned configuration and flanked on each side with integralrelatively closed areas of uniformly distributed fibers, the fibers inboth the open and closed areas being haphazardly disposed. When a fabricof this type is folded around an absorbent pad, as in a catamenialnapkin such as is shown in FIG. 23, the open-patterned, highly permeableportion of the fabric wrapper is located in the central area of the padsurface where the menstrual exudate normally makes contact, permittingrapidpenetration of the exudate into the absorbent pad. This type ofconstruction has particular advantages in that a highly permeablecentral portion of the Wrapper permits rapid fluid penetration at thedesired location. In addition, nonpatterned areas are located laterallyof the patterned area of the pad wrapper to present a soft smoothnon-chafing surface where the wrapped pad is in rubbing contact with thethighs.

The fabric of FIG. 19 comprises a fiber carrying web made up of warp andwoof threads 71 and 73 to which is applied an applique of haphazardlydeposited fibers in a patterned configuration defining a relatively opencentral portion flanked on each side by a relatively closed portion 79.The central portion includes elongate slotlike areas 77, which aresubstantially free of deposited fibers, and intervening riborstrand-like areas 75 made up of substantial fibrous deposits. The fibersthroughout areas 75 and 79 are interbonded, at least in part, to thewarp and woof threads 71 and 73- respectively, and may also be bonded toeach other. The fiber arrangement shown defines a central area of afluid permeability and attractive appearance.

FIG. 20 illustrates an alternate embodiment of the invention wherein aplurality of fibrous strands 80 are obliquely disposed to extend acrossa central longitudinally disposed area to intersect a plurality ofobliquely disposed strands 82 disposed in reversed angularitythereacross. The resulting patterned configuration throughout thecentral area defines a plurality of relatively open areas 81 and 83intermediate the strands thus disposed. A central row of diamond-shapedopenings 81 is flanked on each side in the pattern shown by rows oftriangularly shaped openings 83 to present a fabric of attractiveappearance with relatively high'fluid permeability in the centralportion thereof.

As in the fabric of FIG. 19 the relatively open central area is flankedon either side by relatively closed areas 84 wherein the fibers arehaphazardly but uniformly deposited. Obviously, many variations ofpatterns incorporating adjacent open areas and closed areas can be usedin the longitudinal central portion of the fabric.

The apparatus of FIG. 8 may be utilized to make the fabrics of FIGS. 19and 20 by restricting the patterned area of the patterned screen belt 33t the central longitudinal portion.

FIGS. 21 and 22 are fragmentary representations of another embodiment ofthe fabric with the pattern restricted to the central portion. In thisembodiment no thread carrier web is used, FIG. 21 being a plan viewwhile FIG. 22 is in perspective. The fabric is made up of a patternedcentral portion consisting of a network of independently formedlongitudinally and transversely extending bands 85 and ribbons 87 offibers and open areas 86. The ribbons 87 are formed independently of thebands 85 as in the fabrics of FIGS. and 6. Marginally flanked portions89 consist of haphazardly arranged intermeshed fibers of substantiallyequal distribution to provide relatively closed areas.

The apparatus of FIG. 14 may be used to make the fabrics of FIGS. 21 and22 by restricting the pattern of the patterned screen belt 33a to thecentral longitudinal portion.

FIG. 23 shows the fabric of FIGS. 21 and 22 in use as a wrapper for acatamenial napkin with identifying 14 numbers in FIG. 23 referring tosimilar portions of the fabric FIGS. 21 and 22.

Another example of utility of the described fabric is shown in FIGURE 18where there is represented a form of padding or cushioning material forprotecting goods packaged for shipment. The illustrated example ofpackaging material comprises superposed plies 67, 68, 69, and 70 of allunspun fiber fabric made according to FIGURE 4. The assembled pliesprovide a cushion of substantial thicknes or bulk and very light weight.As indicated in said FIGURE 18, the fiber bearing areas of the assembledplies need not be registered with one another and will neverthelessbuild up a thick soft pad. The plies may be adhesively bonded togetherif desired, but the normal tendency of fibers to cling to each otherprovides ply adhesion which may be sufl icient for many purposes.

The all over cushioning effect obtained by the spaced areas of higherfiber density permits a reduction inthe total amount of fiber employed,thereby attaining econ omy in manufacture.

The various patterned unspun, low density fiber component fabricsillustrated, including the all unspun fiber fabrics of FIGURES 4 and 5,may be used for each of the specific applications mentioned and for manyothers. The fiber patterns illustrated were selected to typify thegeneral character of the fabrics which may be produced according to thisinvention and to facilitate explanation of various means which may beemployed for producing the fabric. Similarly, the specific threadcarrier web constructions shown are selected as representativeconstructions for explanation purposes, and other forms of interlacedand cross thread webs may be used. It is not intended that the scope ofthe invention be restricted to the specific carrier web constructionsdescribed or to. the specific fiber applique patterns described since,as already indicated, an almost limitless number of patterns of networkand other forms may be produced. Modifications of the describedapparatus and method for producing the fabric may also be made whileemploying the principles of the invention. i

In the following claims, unless otherwise indicated, the words carrierweb. are used to signify a supporting web of interwoven threads astypified by gauze, of non-woven webs comprising crossed but notinterwoven threads, of interlaced threads typified by both interwovenand knitted threads, of parallel or other non-crossing threads, and ofother material which provides the desired tensile strength or supportfor the fiber applique. Again, since there is no critical relationshipbetween the amount of fiber in the areas of fiber concentration, such asthe bands 8 and 9 in the FIGURE 1 fabric, and in the areas of fiberpaucity or dearth, such as in the areas 10 in the FIG- URE l fabric, thereference in the appended claims to a relative dearth of fibers is meantto signify a substantial difference in volume of fiber resulting fromthe provision of a significant amount of fibers in some areas and verylittle and even no fibers in other areas. The term network is employedto signify any pattern which results in areas having little or no fiberwholly surrounded by areas of fiber concentration. Also, the wordapplique, unless otherwise indicated, is used to refer to a deposit offibers Whether applied in haphazard or more or less parallel relation toeach other and without reference to the process or means by which thedeposit is formed.

I claim:

1. Non-woven fibrous fabric of a network-like patterned configurationformed by directing a stream of separated fibersonto a partiallyscreened out foraminous member, said fabric consisting of a web-likelayer of haphazardly deposited textile fibers of more than in lengtharranged to define spaced areas throughout which the fibers are sparselydeposited and intervening areas throughout which the fibers aredeposited in sufficient numbers to provide substantially closedrelatively uniform 155 web portions, some of the fibers in saidintervening areas being adhesively interconnected, and the fabric thusformed having a basis weight of 1 to 20 grams per square yard.

2. A non-woven fabric comprising in combination an open mesh thread weband a non-woven web of unspun textile fibers of more than in lengthformed by directing a stream of separated textile fibers partiallyscreened out in patterned configuration onto said thread web to efiectthe deposit thereon of said non-woven web in a predeterminedconfiguration, and means bonding discrete areas of said non-woven web tosaid thread web.

3. The fabric of claim 2 wherein the non-woven web of unspun textilefibers comprises a longitudinally disposed central portion of regularlyspaced open formation and laterally disposed integral portions ofrelatively closed formation.

4. A highly permeable light weight fabric comprising a carrier web andtextile fibers more than in length deposited in a predetermined patternon said carrier web, said fibers being adhesively bonded to said Webthroughout discrete areas, said predetermined pattern including alongitudinally extending central area throughout which said fibers arehaphazardly deposited and interbonded to define open areas:therebetween, and closed marginal areas throughout which the fibers aresubstantially uniformly deposited, said fabric having been formed bycausing said carrier web to intercept a stream of entrained textilefibers which stream had, prior to said interception, been subjected tothe influence of a screening element of patterned configuration withresultant deposit of said textile fibers on said carrier web in thepatterned configuration of said screening element.

5. A sanitary napkin wrapper comprising a carrier web of spaced threadsof relatively high tensile strength, and a thin, non-woven layer ofunspun textile fibers of more than 6" in length anchored to said carrierWeb to pro vide the outer wrapper surface, the fibers being disposed onsaid carrier web in a selected pattern having distinguishable areas inwhich there are respectively, a relative paucity and a concentration offibers, said areas of fiber concentration being fluid permeable and saidareas of fiber paucity being substantially non-resistant to penetrationby fluid, said fabric having been formed by causing said carrier web tointercept a stream of fluid entrained textile fibers which stream had,prior to said interception,

been subjected to the influence of a screening element of patternedconfiguration with resultant deposit of said textile fibers on saidcarrier web in the patterned configuration of said screening element.

6. A sanitary napkin wrapper comprising an open mesh carrier webcomprising two sets of non-woven threads with one set crossing theother, a non-woven applique of unspun textile fibers of more than inlength on one face of said carrier Web, the fibers of said appliquebeing bonded to one set of said threads and tothe cross-over portions ofsaid other set, the adhesive at said cross-over portions also bondingone set of threads to the other, said second mentioned set of threadsbeing substantially free of adhesive intermediate said cross-overportions thereof, the fibers in said applique being disposed in aselected pattern having distinguishable areas in which there arerespectively, a relatively paucity and a concentration of fibers, saidareas of fiber concentration being highly permeable and said areas offiber paucity being substantially non-resistant to penetration bymenstrual fluid, said fabric having been formed by causing said carrierWeb to intercept a stream of fluid entrained textile fibers which streamhad, prior to said interception, been subjected to the influence of ascreening element of patterned configuration with resultant deposit ofsaid textile fibers on said carrier Web in the patterned configurationof said screening element.

References Cited in the file of this patent UNITED STATES PATENTS795,719 Motz July 25, 1905 2,217,126 Meston et a1 Oct. 8, 1940 2,564,689Harwood et al Aug. 21, 1951 2,705,687 Petterson et al. Apr. 5, 19552,705,688 Ness et al. Apr. 5, 1955 2,705,692 Petterson et a1. Apr. 5,1955 2,719,337 Harwood et al Oct. 4, 1955 2,774,687 Nottebohm et al Dec.18, 1956 2,777,779 HarWood et al Jan. 15, 1957 3,047,444 Harwood July31, 1962 FOREIGN PATENTS 17,151 Great Britain July 23, 1909 987,820France Aug. 20, 1951 1,132,933 France Mar. 19, 1957

1. NON-WOVEN FIBROUS FABRIC OF A NETWORK-LIKE PATTERNED CONFIGURATIONFORMED BY DIRECTING A STREAM OF SEPARATED FIBERS ONTO A PARTIALLYSCREENED OUT FORAMINOUS MEMBER, SAID FABRIC CONSISTING OF A WEB-LIKELAYER OF HAPHAZARDLY DEPOSITED TEXTILE FIBERS OF MORE THAN 1/16" INLENGTH ARRANGED TO DEFINE SPACED AREAS THROUGHOUT WHICH THE FIBERS ARESPARSELY DEPOSITED AND INTERVENING AREAS THROUGHOUT WHICH TGHE FIBERSARE DEPOSITED IN SUFFICIENT NUMBERS TO PROVIDE SUBSTANTIALLY CLOSEDRELATIVELY UNIFORM WEB PORTIONS, SOME OF THE FIBERS IN SAID INTERVENING